Fiber Composite Leaf Spring Dry Preform Resin Infiltration
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Solution Overview
Problem
The existing methods for producing fiber composite leaf springs for motor vehicles are complex and costly due to the handling and processing of fibers infiltrated with resin, which requires precise layering and cooling to prevent premature resin reaction and air inclusions, leading to increased production time and potential weaknesses at the edge and end regions.
Innovation Solution
A method involving the use of dry textile layers layered inside a mold tool, where a binder is applied in dry form to fix the shape, followed by resin infiltration in an RTM cavity, allowing for handling and storage of dry preforms and enabling precise shaping and separation of the fiber composite blank before resin hardening, which simplifies the process and improves edge and end region precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fibers are infiltrated with resin before layering, then the fiber composite component achieves proper matrix distribution, but the handling becomes complex and production time increases due to cooling requirements and precision layering demands
Solution Approach 1:
The patent applies preliminary action by layering and shaping the textile layers into a preform before resin infiltration. The preform is prepared in advance with the correct geometry and fiber arrangement, then stored dry until ready for resin injection. This eliminates the need for immediate resin application and cooling, allowing production time to be reduced while maintaining layering precision through the preformed structure.
2Stability of the object's composition
If resin is applied to infiltrate fibers, then the composite structure is formed, but premature resin reaction occurs requiring complex cooling measures
Solution Approach 1:
The patent segments the manufacturing process into distinct stages: preform preparation (dry), resin infiltration, and hardening. By separating the layering/shaping operations from the resin application, the process allows the preform to be prepared and stored without resin, then infiltrated later when ready. This segmentation eliminates the need for cooling systems to prevent premature resin reaction, reducing device complexity while maintaining composition stability.
3Manufacturing precision
If prepegs are handled after infiltration, then the component structure is established, but handling difficulty increases due to sticky resin and precision requirements
Solution Approach 1:
The preform is prepared in advance with all textile layers arranged and shaped to the final geometry before resin infiltration. This preliminary action allows precise positioning and alignment to be achieved while the material is still dry and easy to handle. Once the preform is complete and hardened, it becomes a stable component that can be stored and transported without handling difficulties, eliminating the sticky resin handling problems.
4Reliability
If complex cooling and handling procedures are used, then resin reaction is controlled, but production economy deteriorates
Solution Approach 1:
The process is segmented into dry preform fabrication and subsequent resin infiltration. The preform can be manufactured, inspected, and stored without resin, then infiltrated in a controlled RTM process. This segmentation provides reliable resin reaction control during the infiltration stage while eliminating the need for complex cooling procedures during preform fabrication, significantly improving production economy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method simplifies the handling of fibers, reduces production time, and enhances the precision and quality of the leaf spring's edge and end regions, eliminating the need for complex cooling and handling of infiltrated fibers, resulting in a more economical and precise manufacturing process.
Implementation Method 1
applying a binder in dry form on at least one of the textile layers and fixing the textile layers so as to form a dry preform
Implementation Method 2
infiltrating the preform with resin in an RTM (Resin Transfer Molding) cavity
Implementation Method 3
hardening the resin to produce the leaf spring of individual fibers and a matrix formed of hardened resin surrounding the fibers
Data Source
AI summary
A leaf spring for a motor vehicle is made from a fiber composite component including individual fibers in form of at least two textile layers stacked on top of each other and a matrix made of a duroplastic or thermoplastic resin surrounding the fibers. The resin is hardened in a mold tool by applying pressure and heat. The stacked textile layers are formed inside a mold tool and fixed by a dry binder applied to at least one of the textile layers to form a dry preform. A fiber composite blank is stamped from the preform and subsequently infiltrated with the resin in a RTM cavity and hardened. The binder applied in dry form may only be arranged in certain areas of the textile layers.